Towels of Micro fibers of Polyester/Polyamide Bi-components and the Method of Making

ABSTRACT

A fabric with polyester/polyamide bi-components micro fibers may include a wrap knitted double-sided base fabric with polyester/polyamide bi-components micro fibers that is treated by a chemical splitting process. Both sides of the double-sided base fabric may have at least 10 loop piles per square centimeter. Each loop pile may have at least one single thread loop. The bottom of the loop piles may be connected to the base fabric. The loops may be arranged orderly to form a planar structure that has the feature that the loop piles on one side of the base fabric may have plush-like structures at the top sections. The loops may be fractured by sanding the loops with a sand paper of 200-600 grit at about 1/10 to 5/10 of a thickness of the loop piles to form the plush-like structures.

TECHNICAL FIELD

This invention is related to towels of polyester/polyamide bi-componentsmicro fibers and is in the field of textile fabrics.

BACKGROUND

It is well known that the traditional towels are made of natural fibers:for example cotton fibers. Cotton fibers may facilitate the propagationof bacteria and mildew in a humid environment. In addition, traditionaltowels may lose fibers quickly and may become stiff after being washed.

Micro fibers have the advantages of extra high absorbency, resistance tolinting, resistance to mildew growth, odorless, softness, resistance tocolor fading, easy to clean after usage, resistance to chlorinebleaching and oxidizing bleaching, etc. They are widely used and havegreat performance in automobile maintenance, hotel industry, beautysalons, sports products and products for daily use. Examples of productswith micro fibers may include towels, shower towels, hair-drying bathhats, facial cleaning cloths, household cleaning cloths, and automobilecleaning cloths, etc.

The advantages of micro fibers are as follows: because the micro fibershave very large specific surface areas, the fibers have extremely largesurface area coverage. Micro fibers also have greater chances ofcontacting dusts or grease, and at the same time grease may have greaterchances of infiltrating into the gaps on the surfaces of the microfibers; therefore they have superior cleaning capability. Fabrics withmicro fibers may also penetrate deeply into the pores on the skin andefficiently clean dirt, grease, dead skin, and residuals of cosmetics.Because the diameter of a micro fiber is very tiny, its bendingstiffness is very small; therefore micro fibers are very soft. Gaps ofthe neighboring fibers of ultra-dense fabrics made of micro fibers mayhave a diameter that is between the diameter of a water drop and amicro-drop of water vapor; therefore the ultra-dense fabrics made ofmicro fibers may have the quality of resistance to wetting andbreathability. Fabrics made of micro fibers can also overcome thedisadvantages of the poor wrinkle-resistance of natural fibers, and thepoor breathability of other man-made fibers. These fabrics may last morethan four times over the normal fabrics. Micro fibers have broad scopesof applications in the future.

To make micro fibers with polyester/polyamide bi-components, thesegments are separated by dissolving one of the components, and thenextruded through a spinneret capillary. The cross section of the fibersmay have a unique shape such as a segmented pie or citrus type. Afterthe fabricating process, the fibers may go through a splitting processin an about 5% alkali solution at 110° C. to peel off the polyester andpolyamide, so that micro fibers may be formed. Normal micro fibers havea double-sided loop piles structure. After only one splitting process,the diameter of each fiber is only about 0.1 D. Therefore, the normalfabric has high frictional drag during usage. It is not smooth andeasily to scratch one's hands, so it gives people an uncomfortablefeeling. Especially when the skin is dry or coarse, the uncomfortablefeeling is more prominent. All these restrict the further development offabrics made of micro fibers.

Chinese Patent CN200910260596.8 discloses a method of napping fibers ofartificial leather: peach one side or both sides of the artificialleather made from micro fibers of polyurethane so that the micro fibersof polyester and polyamide on the surface(s) of the leather may curl upto form polyester fluff and polyamide fluff. This napping method cansimultaneously maintain the properties of both types of micro fibers sothat the final product has the properties of both stiffness andsoftness, and the leather may give people fine hand feel. This nappingmethod is directed to plain weave.

An article by Weiyong Li (Development of Raised Sea-Island Bi-componentsMicro Fiber Products, Silk, 2004 (12): 7-9) discloses that theparameters of the napping treatment of the fabrics may be changed basedon the types and styles of the raised sea-island bi-components microfiber products. The main factors affecting the napping treatment are:the grit number of the sanding paper, the rotation speed of the sandingpaper, wrapping angle, the speed of the advancement of the fabric, themoisture content of the fabric and the after-napping treatment methods.The techniques of the napping method affect the style and appeal of thefabric. The familiarity of the operation of the napping machine iscritical to get the desired napping effect. It is also important tomodify the napping techniques according to the situations. For example,if new sanding paper is used, smaller wrapping angle and faster fabricadvancing speed may be used. However, after the sanding paper being usedfor a period of time, bigger wrapping angle and tension, as well aslower fabric advancing speed should be used so that the napped fabricmay have consistent surface characteristics. One example of nappingmethod is: 240-280 grits sanding paper is used, the rotation speed ofthe sanding paper is 800-1000 rpm, and the fabric advancing speed is20-25 meters/min. This method is also directed to plain weave.

SUMMARY

This invention is intended to provide a towel of polyester/polyamidebi-components micro fibers that have an outward plush-like structure atthe top sections of the loop piles of fibers on at least one side of thetowel. The towels made of these fibers are more comfortable to touch,capable of keeping the heat, skin-friendly, high absorbency, soft andstrong.

A towel of polyester/polyamide bi-components micro fibers according tothis invention includes a wrap knitted double-sided base fabric ofpolyester/polyamide bi-components micro fibers that is treated by achemical splitting process. Both sides of the double-sided base fabrichave at least 10 loop piles per square centimeter. Each loop pile mayhave at least one single thread loop. The bottoms of the loop piles maybe connected to the base fabric. The loops of the loop piles may bearranged orderly to form a planar structure having the feature that atleast the loop piles on one side of the base fabric may have plush-likestructures at the top sections of the loop piles. The plush-likestructures may be formed by fracturing the loops of the loop piles fromthe top of the loops of the loop piles inwardly to about 1/10 to 5/10 ofa thickness of the loop piles form the top of the loop piles. Thefractured loops may form outward plush-like structures. In oneembodiment, the sanding paper used for the sanding treatment may be200-600 grits; the rotation speed of the sand paper may be 600 to 1500rpm; the speed of fabric advancement may be 2 to 15 meters per minute,and the sanding angle may be 5 to 70 degrees.

In one preferred embodiment, the loop piles on both sides of thedouble-sided base fabric may have the plush-like structures at the topsections of the loop piles. The positions of the loops of the loop pilesthat are fractured may be the same or different on the two sides.

In one preferred embodiment, the plush-like structure may be made byfracturing the loops from the top of the loop piles inwardly to about ⅓of the thickness of the loop piles from the top of the loop piles.

The sanding process may be accomplished with a typical fabric sandingmachine.

The properties of the method mentioned above may be as follows: for thetowels of polyester/polyamide bi-components micro fibers according tothis invention, the loop piles on at least one side of the base fabricmay have an outward plush-like structure at the top sections of the looppiles. The plush-like structure is formed by fracturing the loops of theloop piles from the top of the loop piles to about 1/10 to 5/10 of thethickness of the loop piles.

In a preferred embodiment, both sides of the base fabric may be sanded.The locations of the sanding process may be the same or different forthe two sides. The sanding positions on the thickness of the loop pilesmay affect the length of the plush-like structure.

In a preferred embodiment, the position of the sanding is from the topsections of the loop piles inwardly to about ⅓ of the thickness of theloop piles. In one embodiment, the fibers of polyester/polyamidebi-components may be formed by four long yarns or threads. Two centerthreads may be polyester fibers, and the two side fibers may bepolyester/polyamide bi-components fibers. The center threads may formthe base fabric and the side polyester/polyamide bi-components fibersform the loop piles. The composition of the polyester/polyamidebi-components may be 80% polyester: 20% polyamide, 70% polyester: 30%polyamide, or 85% polyester: 15% polyamide.

In one embodiment, the composition of the base fabric may have polyesterup to 70-90% of the total weight, and polyamide up to 10-30% of thetotal weight.

A method of printing towels of polyester/polyamide bi-components microfibers may include: warp knitting fabrication—high temperature fixing at210 degrees Celsius—chemical splitting—bleaching—drying/fixing at 160degrees Celsius—napping process—rinsing—drying/fixing at 160 degreesCelsius—printing—drying at 160 degrees Celsius—color fixing at 170degrees Celsius—rinsing—drying/fixing at 160 degrees Celsius—patterncutting—sewing—quality examination/packaging.

A method of dying towels of polyester/polyamide bi-components microfibers may include: wrap knitting fabrication—high temperature fixing at210 degrees Celsius—chemical splitting—dying—drying/fixing at 160degrees Celsius—napping process—rinsing—drying/fixing at 160 degreeCelsius—quality examination/packaging.

Fabrics may be treated with various dying or printing techniquesaccording to different requirements.

The advantages of this invention may be as follows: for the method ofmaking towels of polyester/polyamide bi-components micro fibersaccording to this invention, the loop piles on at least one side of thebase fabric may be fractured from the top of the loop piles and moveinwardly to about 1/10 to 5/10 of the thickness of the loop piles. Thefabric may have an outward plush-like structure at the top section ofthe loop piles. This method is simple and effective, and easily toimplant. The fabrics may be more comfortable to touch, capable ofkeeping the heat, skin-friendly, high absorbency, soft and strong.

DRAWINGS

FIG. 1 shows the structure of the micro fibers according to oneembodiment of this invention.

1. plush-like structure, 2. base fabric, 3 loop piles.

DETAILED DESCRIPTION

The technique scheme of the invention is further described hereinafterby combing the embodiments and the FIGURE.

In one embodiment, the fibers of polyester/polyamide bi-components maybe formed by four threads. Two center threads may be polyester threads,and the two side threads may be polyester/polyamide bi-components microfibers. The center threads may form the base fabric and the sidepolyester/polyamide bi-components micro fibers form the loop piles. Thecomposition of the polyester/polyamide bi-components may be 80%polyester: 20% polyamide.

The towels may be finished with a dying process: wrap knittingfabrication—high temperature fixing at 210 degrees Celsius—chemicalsplitting—dying—drying/fixing at 160 degrees Celsius—nappingprocess—rinsing—drying/fixing at 160 degree Celsius—qualityexamination/packaging.

Example 1

As shown in FIG. 1, in one embodiment, a towel of polyester/polyamidebi-components micro fibers may be a wrap knitted fabric that has adouble-sided base fabric 2 made of polyester/polyamide bi-componentsmicro fibers that are treated by a chemical splitting process. Bothsides of the base fabrics 2 may have loop piles 3. The density of theloop piles 3 may be at least 10 per square centimeter. Every loop pile 3may contain at least 1 single-thread loop. The bottom sections of looppiles 3 are connected to the base fabric 2. A plush-like structure 1 maybe made by fracturing loops from the top of the loop piles 3 inwardly toabout ⅓ of the thickness of the loop piles 3 from the top of the looppiles 3. All the loop piles 3 may have loops fractured at about the sameposition. The fractured fibers may form an outward plush-like structure1. The sanding paper used for the sanding treatment may be 400 grits.The rotation speed of the sand paper may be 1000 rpm, and the speed offabric advancement may be 15 meters per minute, and the sanding anglemay be 40 degrees. The advantages of the towels made from the abovementioned method may be that every loop pile 3 may have outwardplush-like structures 1 from the top of the loop piles 3. The plush-likestructures 1 may be made by fracturing loops from the top of the looppiles 3 inwardly to about ⅓ of the thickness of the loop piles 3. Allthe loop piles may have loops fractured at about the same position.

The composition of the polyester/polyamide bi-components of the towelsmay be 88% polyester: 12% polyamide.

The test results of the towels of example 1 are shown in Table 1.

TABLE 1 Experimental Data of a Sample Grading of Tested PropertiesInspection Criteria Standards Colorfastness to Washing 4.5 AATCC 61-2010Colorfastness to Light 4   AATCC 16-2004 Colorfastness to Water 4.5AATCC 107-2009 Colorfastness to Perspiration 4.5 AATCC 106-2009Absorbency 58%  ASTM D4772-1997

The test results show that the colorfastness and the absorbency of thesample all meet the standards.

Example 2

As shown in FIG. 1, in one embodiment, a towel of polyester/polyamidebi-components micro fibers may be a wrap knitted fabric that has adouble-sided base fabric 2 made of polyester/polyamide bi-componentsmicro fibers that are treated by a chemical splitting process. Bothsides of the base fabrics 2 may have loop piles 3. The density of theloop piles 3 may be at least 10 per square centimeter. Every loop pile 3may contain at least 1 single-thread loop. The bottom sections of looppiles 3 are connected to the base fabric 2. Only the loop piles 2 on oneside of the base fabrics 2 are sanded. The sanding process may start atthe top of the loop piles 3 and moves inwardly to about 1/10 of thethickness of the loop piles 3. The fractured loops of the loop piles 3may form outward plush-like structures 1. The sanding paper used for thesanding treatment may be 500 grits. The rotation speed of the sand papermay be 1200 rpm, and the speed of fabric advancement may be 10 metersper minute, and the sanding angle may be 5 degrees.

The advantages of the towels made from the above mentioned method may bethat every loop piles 3 may have outward plush-like structures 1 at thetop of the loop piles 3. The plush-like structures 1 may be made byfracturing loops from the top to about 1/10 of the thickness of the looppiles 3 from the top.

The composition of the polyester/polyamide hi-components of the towelsmay be 95% polyester: 5% polyamide.

The test results of the towels of example 2 are shown in Table 2.

TABLE 2 Experimental Data of a Sample Grading of Tested PropertiesInspection Criteria Standards Colorfastness to Washing 4 AATCC 61-2010Colorfastness to Light 4.5 AATCC 16-2004 Colorfastness to Water 4.5AATCC 107-2009 Colorfastness to Perspiration 4.5 AATCC 106-2009Absorbency 57.2% ASTM D4772-1997

The test results show that the colorfastness and the absorbency of thesample all meet the standards.

Example 3

As shown in FIG. 1, in one embodiment, the loop piles 3 of the bothsides of the base fabric 2 may be sanded. On one side, the sandingprocess may start at the top of the loop piles 3 and moves inwardly toabout 5/10 of the thickness of the loop piles 3 from the top. Thesanding paper used for the sanding treatment may be 300 grits. Therotation speed of the sand paper may be 800 rpm, and the speed of fabricadvancement may be 8 meters per minute, and the sanding angle may be 70degrees. On the other side, the sanding process is started at the top ofthe loop piles 3 and moves inwardly to about 1/10 of the thickness ofthe loop piles 3. The sanding paper used for the sanding treatment maybe 500 grits. The rotation speed of the sand paper may be 1200 rpm, andthe speed of fabric advancement may be 10 meters per minute, and thesanding angle may be 5 degrees.

The advantages of the towels made from the above mentioned method may bethat the loop piles on both sides of the base fabric 2 may have outwardplush-like structures 1 at the top of the loop piles 3. The fracturedpositions on the loop piles are different, on one side the fracturedposition is at about 5/10 of the thickness and on the other side thefractured position is at about 1/10.

The composition of the polyester/polyamide bi-components of the towelsmay be 80% polyester: 20% polyamide.

The test results of the towels of example 3 are shown in Table 3.

TABLE 3 Experimental Data of a Sample Grading of Tested PropertiesInspection Criteria Standards Colorfastness to Washing 4.5 AATCC 61-2010Colorfastness to Light 4.5 AATCC 16-2004 Colorfastness to Water 4.5AATCC 107-2009 Colorfastness to Perspiration 4.5 AATCC 106-2009Absorbency 57.7% ASTM D4772-1997

The test results show that the colorfastness and the absorbency of thesample all meet the standards.

Example 4

As shown in FIG. 1, in one embodiment, the loop piles 3 of the bothsides of the base fabric 2 may be sanded. The sanding positions are thesame on both sides. The sanding process may start at the top of the looppiles 3 and moves inwardly to about 4/10 of the thickness of the looppiles 3 from the top of the loop piles 3. The sanding paper used for thesanding treatment may be 400 grits. The rotation speed of the sand papermay be 900 rpm, and the speed of fabric advancement may be 8 meters perminute, and the sanding angle may be 50 degrees.

The properties of the towels made from the above mentioned method may bethat the loop piles on both sides of the base fabric 2 may have outwardplush-like structures 1 at the top of the loop piles 3. The fracturedpositions on the loop piles are at about 4/10 of the thickness. Thefractured positions are about the same.

The composition of the polyester/polyamide bi-components of the towelsmay be 70% polyester: 30% polyamide.

The test results of the towels of example 4 are shown in Table 4.

TABLE 4 Experimental Data of a Sample Grading of Tested PropertiesInspection Criteria Standards Colorfastness to Washing 4 AATCC 61-2010Colorfastness to Light 4.5 AATCC 16-2004 Colorfastness to Water 4.5AATCC 107-2009 Colorfastness to Perspiration 4.5 AATCC 106-2009Absorbency 57.9% ASTM D4772-1997

The test results show that the colorfastness and the absorbency of thesample all meet the standards.

What is claimed is:
 1. A method of making fabric withpolyester/polyamide bi-components micro fibers comprising: providing atwo-sided base fabric with polyester/polyamide bi-components microfibers, each side of the base fabric including loop piles in a densityof at least 10 loop piles per square centimeter, each loop pileincluding one or more single thread loops, and bottoms of the loop pilesconnected to the base fabric; and sanding the loop piles on at least oneside of the base fabric, wherein the sanding step starts at a top of theloop piles and move inwardly till about 1/10 to 5/10 of a thickness ofthe loop piles, the sanding step uses a sanding paper of a sanding paperof 200 to 600 grits, a rotation speed of the sanding paper of about 600to 1500 rpm, an speed of the base fabric advancing speed of about 2 to15 meters/min, and a sanding angle of about 5 to 70 degrees.
 2. Themethod of claim 1 further comprising sanding the loop piles on the otherside of the base fabric.
 3. The method of claim 1 wherein positions ofthe sanding step are the same or different for the loop piles on bothsides of the base fabric.
 4. The method of claim 2 wherein positions ofthe sanding step are the same or different for the loop piles on bothsides of the base fabric.
 5. The method of claim 1 wherein the sandingprocess moves till about ⅓ of a thickness of the loop piles from the topof the loop piles.
 6. A fabric with micro fibers made with the method ofclaim 1 comprising: loop piles at least on one side of the fabric havingoutward plush-like structures, wherein the outward plush-like structuresare formed by fractured loops of the loop piles at about 1/10 to 5/10 ofthe thickness of the loop piles from the top of the loop piles.
 7. Thefabric of claim 5, wherein both sides of the fabric have outwardplush-like structures, fractured positions on the loop piles aredifferent on the both sides of the fabric.
 8. The fabric of claim 5,wherein both sides of the fabric have outward plush-like structures,fractured positions on the loop piles are the same on the both sides ofthe fabric.
 9. The fabric of claim 5, loop piles at least on one side ofthe fabric having outward plush-like structures, wherein the outwardplush-like structures are formed by fractured loops of the loop piles atabout ⅓ of the thickness of the loop piles from the top of the looppiles.